Airfoil blades are typically inspected in sections to verify their conformance to the geometric tolerances specified on their nominal design. To maintain the accuracy of geometric error evaluation, in particular, for the position and orientation errors of the airfoil sections, sectional airfoil profiles should be reconstructed from the inspection data points. This paper presents a new method to automatically reconstruct the airfoil profile from unorganized noisy sectional data points of 3D scanned blades. A three-step airfoil profile reconstruction approach is presented. First, the algorithm thins the scattered set of sectional data points by projecting them onto the local curves fitted to them. For this purpose, a recursive weighted local least-squares scheme is proposed to fit local curves within the measurement uncertainty constraint of inspection data. Then, to order the thinned set of data points, the profile polygon is generated and imperfect nodes are modified by evaluation of the angular deviation of edges. Finally, a closed nonperiodic B-spline curve is fitted to the thinned and ordered set of data points to construct the smooth airfoil profile. A series of case studies have been carried out to demonstrate the effectiveness of the proposed airfoil profile reconstruction method. Implementation results have demonstrated that the proposed method is accurate and robust to noise. In addition to blade inspection, other applications such as repair and adaptive machining of aero-engine blades can equally benefit from the proposed method for automatic airfoil profile reconstruction.

This paper presents a novel method for aligning the scanned point clouds of damaged blades with their nominal computer-aided design (CAD) model. To inspect a damaged blade, the blade surface is scanned and the scan data in the form of a point cloud is compared with the nominal CAD model of the blade. To be able to compare the scanned point cloud and the CAD model, they must be brought to a common coordinate system via a registration algorithm. The geometric nonconformity between the scanned damaged blade and its nominal model stemmed from the damaged regions can affect the registration (alignment) outcome. The alignment errors then cause wrong inspection results. To prevent this from happening, the data points from the damaged regions have to be removed from the alignment calculations. The proposed registration method in this work can accurately and automatically eliminate the unreliable scanned data points of the damaged regions from the registration process. The main feature is a correspondence search technique based on the geometric properties of the local neighborhood of points. By combining the average curvature Hausdorff distance and average Euclidean Hausdorff distance, a metric is defined to locally measure the dissimilarities between the scan data and the nominal model and progressively remove the identified unreliable data points of the damaged regions with each iteration of the fine-tuned alignment algorithm. Implementation results have demonstrated that the proposed method is accurate and robust to noise with superior performance in comparison with the existing methods.